A02 MPLD Cylinders SOW 2.docx

US Army Corps of Engineers St. Louis District

Cylinder Rehabilitation Mel Price Lock and Dam

Mel Price Lock and Dam #1 Lock and Dam Way East Alton, IL 62024

SCOPE OF WORK AND TECHNICAL SPECIFICATIONS

June 2023

Scope of Work

1. GENERAL. All products and materials must be fabricated domestically in the United States of America, no substitutions. The work provided for herein consists of furnishing all labor, plant, materials, and equipment required to rehabilitate 1 hydraulic cylinder for Mel Price Lock and Dam, as specified herein and shown on the contract drawings. Cylinder removal and installation is to be accomplished by Government personnel. The Contractor will be responsible for transportation of the cylinder to and from the project.

2. OMISSIONS. This scope of work may duplicate or not cover all specified activities, steps, and/or procedures required to accomplish work. In case of omission, the normal industry standards, practices, specifications and/or guidelines shall prevail. In no instance shall omission be a reason to perform inferior work, produce a less than acceptable product or service, or refuse to perform an intended activity.

3. CONTRACTING OFFICER. The term "Contracting Officer" shall mean the person executing this contract on behalf of the Government, and any other officer or civilian employee who is properly designated Contracting Officer; and the term shall include, except as otherwise provided in this contract, the authorized representative of a Contracting Officer acting within the limits of their authority.

4. WARRANTY. Materials and workmanship shall be warranted by the Contractor for a period of two year from date of acceptance by the Government after rehabilitation. All replacement parts required under the warranty provisions shall be furnished by the Contractor at no additional cost to the Government.

5. PAYMENT. Payment for the cylinder rehabilitation will be made at the contract amount for the applicable item shown in Section B, which price and payment shall constitute full compensation for the work specified herein and shown on the contract drawings for each item.

6. TECHNICAL POINT OF CONTACT. For technical inquiries please call: Kyla James, E.I.T.

314-331-8248

Erik Fisko, Facility Maintenance & Safety Specialist 618-291-6007

7. PLACE OF DELIVERY. The item(s) supplied under this contract shall be delivered F.O.B. Destination to:

U.S. Army Corps of Engineers St. Louis District Mel Price Lock and Dam #1 Lock and Dam Way East Alton, IL 62024 POC: James Adden, Navigation Area Manager, 636-899-1543 Allen Barnes, Lock Master, 501-730-3093

Deliveries are accepted Monday – Friday, 0800-1630.

8. PERIOD OF PERFORMANCE. Date of award through 24 March 2025

9. GENERAL SECURITY REQUIRMENTS AND GUIDANCE:

a) The security requirements described below apply to all contract personnel (including employees of the prime Contractor (“Contractor”) and all subcontractor employees) supporting the performance requirements of this contract. The Contractor is responsible for compliance with these security requirements. Questions regarding security matters shall be addressed to the designated Government representative (e.g., Contracting Officer Representative (COR), Requiring Activity (RA) representative, or Contracting Officer (if a COR or other RA representative is not appointed)). Contract personnel are critical to the overall security and safety of US Army Corps of Engineers (USACE) installations, facilities and activities, and security awareness training contributes to those efforts. The Department of Defense (DoD) and Army security training requirements specified below, if applicable, are performance requirements; all applicable contract personnel shall complete initial training within 30 days of contract award or the date new contract personnel begin performance on the contract. Within five business days from the completion of training, the Contractor shall provide written documentation (e.g., email or memorandum) to the Government representative. The documentation shall include the names of contract personnel trained and which training they completed; the Contractor shall maintain training records as part of their contract files and be prepared to provide copies of training certificates to the Government representative. Contractor personnel and vehicles are subject to search when entering federal installations. Additionally, all contract personnel shall comply with Force Protection Condition (FPCON) measures, Random Antiterrorism Measures (commonly referred to as “RAMs”), and Health Protection Condition (HPCON) measures. The Contractor is responsible for meeting performance requirements during elevated FPCON and/or HPCON levels in accordance with applicable RA plans and procedures --this includes identifying mission essential and non-mission essential personnel. In addition to the changes otherwise authorized by the changes clause of this contract, should the FPCON or HPCON levels at any individual facility or installation change, the Government may implement security changes that affect contract personnel. The Contractor shall ensure all contract personnel are aware of their security responsibilities, including any site-specific requirements identified in local policies or procedures.

10. ANTITERRORISM/OPERATIONS SECURITY:

a) Suspicious Activity Reporting Training (e.g. iWATCH, CorpsWatch, or See Something, Say Something): The contractor and all associated sub-contractors shall receive a brief/training (provided by the RA) on the local suspicious activity reporting program. This locally developed training will be used to inform employees of the types of behavior to watch for and instruct employees to report suspicious activity to the project manager, security representative or law enforcement entity. This training shall be completed within 30 calendar days of contract award and within 30 calendar days of new employees commencing performance with the results reported to the COR NLT 5 calendar days after the completion of the training.

b) Pre-screen candidates using E-Verify Program: The Contractor must pre-screen Candidates using the E-verify Program (http://www.uscis.gov/e-verify) website to meet the established employment eligibility requirements. The Vendor must ensure that the Candidate has two (2) valid forms of Government issued identification prior to enrollment to ensure the correct information is entered into the E-verify system. An initial list of verified/eligible Candidates must be provided to the COR no later than three (3) business days after the initial contract award.

a. When contracts are with individuals, the individuals will be required to complete a Form I-9, Employment Eligibility Verification, with the designated Government representative. This Form will be provided to the Contracting Officer and shall become part of the official contract file.

11. SUSTAINABLE OPPORTUNITY:

a) Bio-based: The United States Department of Agriculture (USDA) designates certain biobased products for federal procurement and specifies minimum biobased content levels for those products. Any designated product that is being offered or supplied under this contract shall meet USDA BioPreferred’s minimum biobased content level. Visit the BioPreferred web site https://www.biopreferred.gov/BioPreferred/faces/pages/ProductCategories.xhtml for the complete list of designated products and the associated minimum biobased content level requirements.

12. WORK PERFORMANCE REQUIREMENTS: The Contractor will be responsible for transportation of the cylinder to and from the project. The rehabilitation of the cylinder by the Contractor will include but no limited to the following:

· Replacement of seals, cap screws, bronze rod gland, and holding valve cartridge at a minimum. Cap screws must be torqued down with equipment to reach an accurate torque value.

· A full inspection of all parts and the delivery of an inspection report to be provided within two weeks of pick up. The Government will then decide as to what additional repairs are to be made.

· The input port at both the rod end and cap end should be made flat and drilled and tapped for a four-bolt flange connection from the hose. This will eliminate the threaded connection that is currently leaking in the field.

· Repaint the cylinder and exposed components.

· The cylinder must be filled with hydraulic fluid prior to delivery on site.

· A technical representative from the factory must be on site to provide guidance during reinstallation of the cylinder into the recess.

The replacement of the hydraulic lines by the Contractor will include the following:

· Remove hosing and stainless-steel tubing from the cylinder up to the 90 degree bend of pipe through the lock wall for both the main and auxiliary locks.

· Weld on transition pipe to connect new pipe and tubing.

· Install new stainless-steel pipe, four bolt flange connections, hose, and both ball valves at the cylinder (rod end and cap end).

· All new hose installed should be the same length and a spare provided.

13. SUBMITTALS. Government approval is required for submittals with a "G" designation; submittals not having a "G" designation are for information only. When used, a designation following the "G" designation identifies the office that will review the submittal for the Government. Submit the following in accordance with Section 01 33 00 SUBMITTAL PROCEDURES. Contractor shall submit pre-construction submittals within 7 days after contract award:

a. Equipment Manufacturer's And Fabricator's Qualifications

b. Erecting Engineer Qualifications; G

14. INSPECTION. Upon completion of each cylinder, the contractor and Government shall inspect all work for functionality and operation. The contractor shall be responsible for repair or replacement of all damages or non-functioning components prior to final acceptance and repair or replacement of all damages to the work site resulting from work performed under this contract.

15. DRAWINGS AND SPECIFICATIONS. The following plans and specifications listed herein consists of detailed work performance requirements to include submittals, testing, and inspections requirements:

A. SECTION B – BID SCHEDULE

B. SECTION C - REHABILITATION OF HYDRAULIC POWER SYSTEM

C. SECTION D - REFERNCE DRAWINGS

D. APPENDIX B – HYDRAULIC CYLINDER WORK SCHEDULE

SECTION B - Bid Schedule

NOTE: Prices must be on a firm fixed basis.

UNIT

ITEM DESCRIPTION QUANTITY U/I PRICE AMOUNT

0001 Miter Gate Cylinder Rehabilitation

1 EA

NOTE: Each (EA) price and payments shall constitute full compensation for all costs associated with furnishing all required components of each Bid Item.

All costs for Bid Items No. 0001 shall include furnishing all plant, labor, material, and equipment and performing all operations required to rehabilitate, assemble, deliver, and test the cylinder assemblies.

OPTIONAL BID ITEMS. The Contracting Officer will direct the optional bid item work as needed. The Contractor shall perform the appropriate work ONLY when directed by the Contracting Officer. The Government is not obligated to request any work under any optional item(s). The bid prices for each optional item shall represent your firm price to perform that service.

Payment will be made ONLY for work requested and performed to the Government’s satisfaction. The start of the delivery schedule outlined in the specifications for optional bid items shall be considered the date of receipt of a written notice that the optional bid item is exercised by the Contracting Officer.

SECTION C - REHABILITATION OF HYDRAULIC POWER SYSTEMS

04/14

PART 1 GENERAL

1.1 SUMMARY

The work covered by this section of the specifications consists of detailed requirements for the rehabilitation, fabrication, shop assembly, testing, and delivery of the hydraulic power cylinders and installation of accessories for operation of the culvert valves and miter gates as specified and as shown.

1.2 PRODUCTS INSTALLED BUT NOT SUPPLIED

Pursuant to Contract Clause GOVERNMENT-FURNISHED PROPERTY (SHORT FORM), the Government will furnish to the Contractor the following property to be incorporated in the work. Such property will be furnished at the project site for delivery acceptance: complete hydraulic cylinder assemblies of number identified in the contract line item and accessories. Verify the quantity and condition of such Government-furnished property when delivered, acknowledge receipt thereof in writing and in case of damage to or shortage of such property, report within 24 hours, in writing, such damage or shortage.

1.3 LUMP SUM PRICES

1.3.1 Payment

Payment will be made for costs associated with the hydraulic power system as specified in the bid schedule.

1.3.2 Unit of Measure

Unit of measure: lump sum for quantities shown in bid schedule.

1.4 REFERENCES

The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the text by the basic designation only.

AMERICAN SOCIETY FOR NONDESTRUCTIVE TESTING (ASNT)

ANSI/ASNT CP-189 (2016) ASNT Standard for Qualification and Certification of Nondestructive Testing Personnel (ANSI/ASNT CP-105-2006)

AMERICAN WELDING SOCIETY (AWS)

AWS D1.1/D1.1M (2015; Errata 1 2015; Errata 2 2016) Structural Welding Code - Steel

ASME INTERNATIONAL (ASME)

ASME B16.11 (2016) Forged Fittings, Socket-Welding and Threaded

ASME B31.1 (2016; Errata 2016) Power Piping

ASME B36.19M (2004; R 2015) Stainless Steel Pipe

ASME B40.100 (2013) Pressure Gauges and Gauge Attachments

ASME BPVC SEC IX (2010) BPVC Section IX-Welding and Brazing Qualifications

ASME BPVC SEC VIII D1 (2015) BPVC Section VIII-Rules for Construction of Pressure Vessels Division 1 ASTM INTERNATIONAL (ASTM) ASTM A108 (2013) Standard Specification for Steel Bar, Carbon and Alloy, Cold-Finished

ASTM A181/A181M (2014) Standard Specification for Carbon Steel Forgings, for General-Purpose Piping

ASTM A182/A182M (2016a) Standard Specification for Forged or Rolled Alloy-Steel Pipe Flanges, Forged Fittings, and Valves and Parts for High-Temperature Service

ASTM A193/A193M (2016) Standard Specification for Alloy-Steel and Stainless-Steel Bolting Materials for High-Temperature Service and Other Special Purpose Applications

ASTM A194/A194M (2017) Standard Specification for Carbon Steel, Alloy Steel, and Stainless-Steel Nuts for Bolts for High-Pressure or High-Temperature Service, or Both

ASTM A216/A216M (2016) Standard Specification for Steel Castings, Carbon, Suitable for Fusion Welding, for High-Temperature Service

ASTM A266/A266M (2013) Standard Specification for Carbon Steel Forgings for Pressure Vessel Components

ASTM A312/A312M (2017) Standard Specification for Seamless, Welded, and Heavily Cold Worked Austenitic Stainless-Steel Pipes

ASTM A325 (2014) Standard Specification for Structural Bolts, Steel, Heat Treated, 120/105 ksi Minimum Tensile Strength

ASTM A354 (2017) Standard Specification for Quenched and Tempered Alloy Steel Bolts, Studs, and Other Externally Threaded Fasteners

ASTM A516/A516M (2010; R 2015) Standard Specification for Pressure Vessel Plates, Carbon Steel, for Moderate- and Lower-Temperature Service

ASTM A519/A519M (2017) Standard Specification for Seamless Carbon and Alloy Steel Mechanical Tubing

ASTM A536 (1984; R 2014) Standard Specification for Ductile Iron Castings

ASTM A564/A564M (2013) Standard Specification for Hot-Rolled and Cold-Finished Age-Hardening Stainless-Steel Bars and Shapes

ASTM A574 (2017) Standard Specification for Alloy Steel Socket-Head Cap Screws

ASTM A576 (1990b; R 2012) Standard Specification for Steel Bars, Carbon, Hot-Wrought, Special Quality

ASTM A659/A659M (2012; R 2017) Standard Specification for Commercial Steel (CS), Sheet and Strip, Carbon (0.16 Maximum to 0.25 Maximum Percent), Hot-Rolled

ASTM A705/A705M (2013) Standard Specification for Age-Hardening Stainless-Steel Forgings

ASTM B505/B505M (2014) Standard Specification for Copper-Base Alloy Continuous Castings

ASTM B584 (2014) Standard Specification for Copper Alloy Sand Castings for General Applications

ASTM D3951 (2015) Commercial Packaging

ASTM E165/E165M (2012) Standard Practice for Liquid Penetrant Examination for General Industry

ASTM F844 (2007a; R 2013) Washers, Steel, Plain (Flat), Unhardened for General Use

INTERNATIONAL ORGANIZATION FOR STANDARDIZATION (ISO)

ISO 16889 (2008) Hydraulic Fluid Power - Multi-Pass Method for Evaluating Filtration Performance of a Filter Element

ISO 4021 (1992) Hydraulic Fluid Power - Particulate Contamination Analysis - Extraction of Fluid Samples from Lines of an Operating

System

(2017) Hydraulic Fluid Power - Fluids - Method for Coding the Level of Contamination by Solid Particles

(2002) Hydraulic Fluid Power - Fluid Contamination - Determination of Particulate Contamination by the Counting Method Using an Optical Microscope

(2008) Fluid Power Systems

- Vocabulary

SAE J514 (2012) Hydraulic Tube Fittings

SAE J517 (2016) Hydraulic Hose

SAE J518-1 (2013) Hydraulic Flanged Tube, Pipe, and Hose Connections, 4-Screw Flange Connection Part 1: 3.5 MPa to 35 MPa (Code 61)

1.5 SUBMITTALS

Government approval is required for submittals with a "G" designation; submittals not having a "G" designation are for information only. When used, a designation following the "G" designation identifies the office that will review the submittal for the Government. Submit the following in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:

SD-01 Preconstruction Submittals

Equipment Manufacturer's And Fabricator's Qualifications Erecting Engineer Qualifications; G SD-02 Shop Drawings

Schematic Drawings and Data; G SD-03 Product Data Materials and Mechanical Equipment; G Shop Assembly and Testing Procedures; G Piping Installation; G Cleaning and Flushing; G Field Test Plan; G SD-06 Test Reports

Post-disassembly Inspection Report; G Shop Testing Report Field Testing Report

SD-10 Operation and Maintenance Data Operation and Maintenance

1.6 SCHEMATIC DRAWINGS AND DATA

1.6.1 Shop Drawings

Include fabrication and shop assembly drawings in the detailed shop drawings. The drawings must show complete details of materials, tolerances, machined surface finishes, connections, and welding details. Detail any component part of fabricated items omitted on the shop drawings. If departures from the contract drawings are deemed necessary by the Contractor, submit details of such departures, including changes in related portions of the project and reasons thereof, with the shop drawings. Provide fabrication and assembly drawings to 1-1/2 inch = 1 foot-0 inch or larger scale.

1.6.2 Piping Drawings

Provide piping drawings showing the installed hydraulic lines in schematic format identifying all items of equipment incorporated in the system.

Include details of all pipe supports.

1.6.3 Shop Assembly Drawings

Provide shop assembly drawings with details for connecting the adjoining fabricated components in the shop to ensure satisfactory field installation.

1.6.4 Product Data

Provide product data on the materials, stainless steel piping, hose, and valves. Include catalog cuts and outline dimensions for all valves, valve controls and other accessories.

1.6.5 Shop Assembly and Testing Procedures

Provide procedures for shop testing and operating test for all testing outlined in paragraphs SHOP ASSEMBLY AND TESTING and FIELD TESTS AND INSPECTIONS. Submit data collected during shop testing in a shop testing report. Provide records of all adjustments and final settings for all hydraulic components in the system.

1.6.6 Cleaning and Flushing Procedures and Results

Provide detailed procedure for the cleaning and flushing of hydraulic cylinders and piping as outlined in paragraph CLEANING AND FLUSHING, not less than 10 days before start of operations.

1.7 DELIVERY, STORAGE, AND HANDLING

1.7.1 Packaging

Do not prepare the hydraulic cylinders for shipment until they have been inspected and accepted for shipment at origin by the Contracting Officer, unless inspection has been waived in writing. Ship each hydraulic cylinder completely assembled.

Provide the assembly with adequate protective pads, supports, and blocking and securely restrained to prevent distortion or damage to the painted surfaces in transit. Any loss or damage during shipment, including damage to the painted surfaces, is the Contractor's responsibility; replace or repair without cost to the Government. Pack all accessories and spare parts separately in containers plainly marked "ACCESSORIES ONLY," or "SPARE PARTS ONLY." Place a packing list, listing the contents of each container, in a moisture-proof envelope and securely fasten to the outside of the container. Standard commercial packaging in accordance with ASTM D3951 will be acceptable except where a different method or standard of packaging is specified.

1.7.2 Shipping, Preservation, and Storage

Packing, crating, cradles, etc., necessary to ensure safe shipment are the responsibility of the Contractor and become the property of the Government upon delivery of the equipment. The hydraulic cylinders must be filled with the specified hydraulic fluid. Securely cap remaining ports with blank flanges to prevent the entrance of foreign matter. Prevent damage to the cylinder and piston rod resulting from the rod flexing up and down in the cylinder during transport. Submit a proposal for controlling movement of the piston rod for approval. Adequately protect machined surfaces from corrosion and physical damage. Protect equipment delivered and placed in storage from the weather, humidity, temperature variation, dirt and dust, or other contaminants.

1.8 WARRANTY

All equipment must be guaranteed for a period of 2 years from the date of acceptance by Government after rehabilitation. Guarantee replacement parts for 2 years from date of replacement. Provide Warranty against defective materials and workmanship. Upon receipt of notice from the Government of failure of any of the parts during the warranty period, provide new replacement parts promptly at no additional cost to the Government.

1.9 QUALITY ASSURANCE

1.9.1 Manufacturer and Assembler

Rehabilitating and assembly of the miter gate and culvert valve hydraulic cylinders shall be performed by a Contractor and fabrication company that has been normally and regularly engaged in assembly, and manufacture of heavy machinery over the preceding 10 years. Submit equipment manufacturers and fabricator's qualifications

PART 2 PRODUCTS

2.1 MATERIALS AND MECHANICAL EQUIPMENT

2.1.1 General

Provide materials and mechanical equipment that conform to the requirements indicated or specified, and if not specified, furnish materials and mechanical equipment of the best commercial grade quality suited to the intended use and as approved. Permanently display the manufacturer's name, address, and catalog number on a nameplate securely attached to each major item of equipment.

Submit data specifications and assembly drawings showing sizes, ratings, parts and material lists, overall dimensions, and mounting dimensions with the product data.

2.1.2 Standard Products

Where items are referred to hereinafter as "similar and equal to" a particular manufacturer's product, such references have been made merely as a convenient method of indicating the type of material or equipment required, with no intention of asserting superiority thereof. The standard product of any reputable manufacturer regularly engaged in the commercial production for at least 2 years prior to this solicitation of the type and quality of material or equipment referred to will not be excluded based on minor differences, provided essential requirements of the specifications relative to materials, capacity, and performance are met. Furnish performance capacities and other pertinent information concerning the manufacturer's "equal to" standard products intended for incorporation in the work. "Equal to" standard products installed or used without such approval are at the risk of subsequent rejection.

2.1.3 Hydraulic Cylinders

The outside of the finished cylinder must be turned concentric with the bore, and the interior honed to the dimensions, tolerances, and finish shown. Flanges must be parallel to the cylinder, parallel and perpendicular to the cylinder center line. Tolerances must be as shown. Stress relief heat treat the cylinder after completion of all welding. The assembled cylinder must be of such straightness that the piston and rod move smoothly therein without any indication of binding or tight spots. Surface finishes as indicated.

2.1.3.1 Piston Bronze Overlay

Detailed micrometer measurements shall be taken of cylinder piston prior to repair of bronze overlay. After rebuilding of surface, overlay shall be machined and polished to a 8 micro-inch finish or better.

2.1.3.2 O-Ring Seals

Use O-ring seals of Buna N and designed for 5000 psi service. New urethane backup rings shall be provided for O-rings where originally used.

2.1.3.3 Rod Wiper/Scraper

Provide a high-strength polyurethane scraper ring which will withstand the impact and the abrasion of materials adhering to the piston rod. Split and retain the scrapers with split, bolted retainer to facilitate replacement without removal of the rod end clevis.

2.1.3.4 Piston Rod Seals

Provide low leakage V-ring, nonadjustable gland type piston rod seals, designed for 5000 psi service.

2.1.3.5 Rod Seal Gland and Locking Device Flange

Fabricate the rod seal gland and locking device flange from bronze conforming to ASTM B505/B505M, Alloy No. C95400 or C93200. The ice scraper, attached to the gland, must conform to ASTM B584, Alloy No. C86300.

2.1.4 Valves

Valves must have a minimum pressure rating of 3000 psi unless stated otherwise. Where possible, manifold mount valves. Manifold mounted valves must be either cartridge type or subplate mounted. Non manifold mounted valves 1 inch or larger must have socket-welded piping connections. Valves must be specifically designed and rated for hydraulic system applications.

2.1.4.1 Shut-Off Valves

Provide in-line mounted, stainless steel, lever operated, ball type. Shut-off valves for all other lines must be ball type, match the line size, and have a maximum allowable working pressure of 3000 psi. The valve ends must have socket-weld pipe connections and be drilled to receive SAE Code 61 flanges. Provide a removable operating lever for each valve. Valves must be specifically designed and rated for hydraulic system applications. Provide with stainless steel valve trim including handles. The valves must have replaceable seats and be repairable without disturbing the welded connections.

2.1.4.2 Holding Valves

Furnish and install replacement holding valve cartridges into existing holding valves.

2.1.5 Piping

Design piping and hose for a working pressure of 3000 psi. 2-inch diameter pipe is required. Provide external cylinder piping as indicated. Weld pipe as indicated. Provide power piping equal or exceeding the requirements of ASME B31.1, and subsequent addenda unless otherwise specified herein or indicated.

2.1.5.1 Pipe

Use seamless stainless-steel conforming to ASME B36.19M and ASTM A312/A312M, Grade TP304. The piping weight class must be Schedule 80.

2.1.5.2 Pipe Fittings

Use the socket welding type pipe fittings conforming to ASME B16.11 and made of stainless-steel conforming to and ASTM A182/A182M, Grade F304. Provide pressure class 3000 pounds. Conform flanges to ASTM A182/A182M with the grade suitable for the pipe to which attached. Threaded fittings are not allowed.

2.1.5.3 Unions

Provide four bolt split flanges with Buna N O-rings for the unions.

2.1.5.4 Hose

All flexible hose must have an inside diameter to match the line size to which it is to be connected to, minimum working pressure the hose must be rated not lower than the system operating pressure indicated with a safety factor of 4. Provide hose conforming to SAE J517, 100R13. The hose must be for general industrial use in hydraulic systems with petroleum base hydraulic fluids. The construction must be a synthetic rubber tube with spiral wire reinforcements and a synthetic rubber cover. Each hose must be of the same length. Each end of the hose must have a straight split stainless steel flange fitting conforming to the requirements of the standard, SAE J518-1, Code 61. Design fittings specifically for use with the hose selected and as recommended by the hose manufacturer. Install the fittings using the internal skive crimp method. Make fittings of Steel, plated to meet an ASTM B117 salt spray test of 500 hours or greater and of the reusable type. Fit the hose with a nylon sleeve to protect and prevent abrasion of the hose cover.

Maintain minimum bending radii. The hoses when installed must appear neat and not kink or have sharp bends and must not rub, bind or ride over one another through the entire motion of the cylinder. Hoses must be tailored fit without excess or rubbing on existing work. Protect the finished surfaces prior to installation of the flanges.

2.1.6 Bolts, Nuts, and Washers

2.1.6.1 Carbon Steel Bolts and Nuts

Conform to ASTM A354, Grade BC, with ASTM A194/A194M, Grade 2H nuts. Structural bolted connections carrying primary loads must be made with ASTM A325 bolts.

2.1.6.2 Stainless Steel Bolts and Nuts

Conform to ASTM A193/A193M, Grade B8, with ASTM A194/A194M, Grade 8 nuts.

2.1.6.3 Flat Washers

Conform to ASTM F844.

2.1.7 Hydraulic Fluid

The hydraulic fluid to be used during shop testing, to fill the cylinders before shipment, flush the system after installation, and to fill the complete hydraulic system must be Conoco Megaflow AW HVI hydraulic oil an all-weather type of hydraulic oil which has a high viscosity index, low pour point, rust and oxidation inhibitors, and antifoam properties. The oil must have an ISO viscosity grade of 46 and a pour point of minus 45 deg F. All hydraulic fluid must be new and clean.

2.2 SHOP ASSEMBLY AND TESTING

Completely shop assemble and test each hydraulic power system insofar as is possible using temporary piping and wiring to determine the correctness of fabrication and the matching of component parts to ensure acceptable operation after field erection. Perform shop tests in the presence of a representative of the Contracting Officer, unless otherwise authorized in writing.

2.2.1 Cylinder Tests

Fill each cylinder with the specified hydraulic fluid, taking care to exclude all air. Then, hydrostatically test each cylinder at 5,000 psi for a minimum of 4 hours. With the rod and piston fully retracted, and the pressure applied to the lower side of the piston, observe the upper end for leakage past the piston. With the rod and piston fully extended, and the pressure applied to the upper side of the piston, observe any leakage past the piston. Any leakage past the seals is cause for rejection. Extend the cylinder rod and piston and observe for smooth, even travel. Any operational problems or source of leakage to the outside of the cylinder is cause for rejection.

2.3 MANUFACTURER PREPARATION BEFORE SHIPMENT

2.3.1 Flushing Hydraulic Cylinders

Clean, flush and fill hydraulic cylinders with new oil before they leave the manufacturing facility.

2.4 PAINTING

Remove existing coating before painting. Shop prime and coat all exposed exterior surfaces of assemblies and equipment except stainless steel, synthetic rubber, and plastic. Insofar as is practicable, apply the complete coating system to individual components and items before assembly to ensure complete coverage and maximum protection against corrosion.

Paint shop assembled equipment prior to any storage or shipment. Do not paint aluminum, stainless steel or non-ferrous surfaces, except as approved by the Contracting Officer. Paint equipment with system of zinc rich primer, epoxy base coat, and urethane topcoat for a completed system dry film thickness of not less than 8 mils, subject to approval by the Contracting Officer. Repair chips, scratches, and other damage to shop-applied painted surfaces in the field.

2.5 SPECIAL TOOLS

Provide all special tools necessary for the proper rehabilitation, operation, maintenance, assembly and disassembly of the machinery in a location and in a manner as directed by the Contracting Officer. Special tools include those indicated and the following:

Note: Provides safety in the cylinder disassembly and reassembly Tuxco Hydraulic Cylinder Servicer

2.6 SPARE PARTS

Furnish the following spare parts with the hydraulic system. Also provide any additional spare parts recommended by the manufacturers and not otherwise included in the listing.

Holding Valve Cartridge (qty 1)

PART 3 EXECUTION

3.1 EXAMINATION

After visiting the site and becoming thoroughly familiar with all details of the work and working conditions, verify dimensions in the field, and then advise the Contracting Officer of any discrepancies prior to performing any work. The Contractor is specifically responsible for the coordination and proper relation of the contracted work to the structure and work of all trades.

3.2 CYLINDER REHABILITATION

3.2.1 Disassembly and Inspection

Completely disassemble the cylinder and inspect all parts for wear and mechanical damage more than industry recommended tolerances. Notify the Contracting Officer when the cylinder disassembly is completed, and all measurements and evaluations are complete. Provide an post-disassembly inspection report containing a list of recommended repairs to the cylinder in addition to those specified herein. The Contracting Officer shall have 14 days to inspect the disassembled cylinder and discuss with the Contractor the recommendations. Any repair work in addition to that specified herein, shall be performed as a modification to this contract, which will be negotiated after the recommendation of repairs report is reviewed by the Government. Visually inspect the piston and piston rod for any pitting, gouging, or other physical damage and cracks and document in inspection report.

3.2.2 Cylinder Tubes

Hone the bore to a surface finish compatible with the seals being used to result in zero leakage past the seals.

3.2.3 Parts for Replacement

Replace at a minimum, all bearings, bushings, and seals. Packing, gaskets, and seals shall be replaced with equivalent components to provide zero leakage. Bronze rod support bearing shall be replaced with SAE 660 bronze.

3.2.4 Fastener Replacement

All end cap bolting shall be replaced with hex head cap screws and nuts conforming to ASTM A490 Type 1 coated in Dacromet or similar for corrosion protection.

3.2.5 Cylinder Pressure Connections

Threaded hydraulic supply pressure connections shall be replaced with SAE Code 61 flanges. Cylinder body shall be machined flat and drilled and tapped for four bolt connection.

3.3 INSTALLATION

Installation of the cylinders to be by others. The Contractor's Erecting Engineer must be on site during all installation procedures.

3.4 POWER PIPING

The general arrangement of the hydraulic piping is as indicated. Arrange the piping such as to raise and lower the culvert valves, and to close and open the culvert valves or miter gates, when the valve spools are positioned as indicated.

3.4.1 Piping Installation

Install the system complete including all necessary valves, fittings, and pipe accessories. All joints must be tight and successfully pass the test hereinafter specified. Submit details of pipe supports and anchors not indicated. Adequately support all lines at intervals not greater than 10 feet or as otherwise indicated. Install hangers and supports using machine bolts and masonry anchors caulked in drilled holes in the masonry or by using machine bolts and expansion shields. Ream and remove burrs from all cut ends of pipe. Remove metal particles from the reaming operations and thoroughly clean ends of pipe before proceeding with the work. Tightly always plug all piping except when work is being performed on a pipe. Clean the pipe sleeves, recesses and trenches of all debris and thoroughly wash with a high-pressure stream of water before any piping is installed. Drilling, chipping, or grinding of concrete in close proximity of any piping being installed is not permitted. Repeat washing out of the sleeves, recesses, and trenches from time to time as necessary. Store valves in a clean, dry place and protect against moisture. Mitering of joints for elbows and notching of straight runs of pipe for tees is not permitted.

3.5 CLEANING AND FLUSHING

During demolition and assembly, securely cover all openings to avoid the entrance of abrasives, dirt, metal chips, and other foreign materials into the hydraulic system through open ends of piping, tubing, and ports of the components. Submit a detailed cleaning and flushing the system procedure not less than 10 days before start of cleaning operations. Use the same hydraulic fluid for flushing as approved for final filling. Include a detailed description of the equipment, materials, hydraulic fluid, temperatures, and duration of each phase of the flushing in the procedures. When flushing is completed, fill with the specified hydraulic fluid.

3.7 ERECTION ENGINEER

Obtain the services of an experienced erection engineer who is regularly employed by the hydraulic cylinder/power unit manufacturer to supervise the installation, start-up, adjustment and operation, and testing of the equipment provided. The erection engineer must furnish a signed statement stating that the final installation and start-up of the hydraulic power system has been inspected, witnessed, and complies fully with the manufacturer's warranty requirements. Following completion of the work the erecting engineer must instruct representatives of the Government in the operation and maintenance of the system. These field instructions must cover all items contained in the bound instructions. Do not conduct instruction until Operation and Maintenance Manuals are approved.

3.8 FIELD TESTS AND INSPECTIONS

3.8.1 Field Test Plan

Submit procedures for field testing and proposed testing program, at least four weeks prior to the first scheduled test, to ensure agreement as to personnel required and scope of the testing program and submit the field test report template. Notify the Contracting Officer at least two weeks before any field testing is to be conducted. Conduct testing in the presence of the Contracting Officer unless waived in writing. Conduct testing under the direction of the erection engineer or manufacturer's representative. Submit data collected during field testing in a field-testing report.

3.8.2 Pipe Pressure Test

Subject pressure piping and tank line piping to a test pressure of 3000 psi for pressure piping. Subject the head end of the cylinder and manifold to a test pressure of 3000 psi. Maintain the test pressure for 12 hours. Isolate or remove any equipment that might be damaged by this pressure to prevent damage. Make tests using the hydraulic oil specified. Under these tests there must be no leakage in the system. Carefully examine welded, flanged, flared, and threaded connections and wipe for leakage, also inspect lines for evidence of deflection caused by inadequate anchorage. No leakage or deflection is allowed. During the tests, take care to avoid subjecting equipment to pressure in excess of their capacities. Correct any defects or damage to any part of the hydraulic system and conduct retest.

3.8.3 Final Acceptance Tests

In preparation for the final acceptance tests, and after completion of the installation and proof tests, operate the hydraulic power system to prove acceptability. Conduct preliminary tests at minimum pressures and velocities until initial adjustments have been proven safe for normal operation. Details of all operations must be constantly monitored for signs of impending trouble and corrections must be made as necessary to prevent damage to the equipment. At such time as the Contracting Officer may direct, conduct the following complete acceptance tests on the hydraulic power system for approval. Any deficiency or maladjustment disclosed by the tests must be corrected immediately and the test repeated until satisfactory results are obtained. No subsequent tests will be permitted until all preceding tests have been completed satisfactorily.

Upon completion of the final acceptance tests, furnish a written statement that the hydraulic power system has been field tested and meets all operational requirements.

3.8.3.1 Initial Start-Up

Inspect the hydraulic reservoir to ensure that the fluid is at the proper level. Test start the hydraulic pumps using the controls at the control console. Inspect the pump for proper operation and discharge pressure.

3.8.3.2 Combined System Tests

After final assembly and installation of the machinery, operate each assembly of operating machinery individually as nearly as practicable under its normal operating conditions for a minimum of 3 open/close cycles; and demonstrate that each assembly is in proper working order and free from defects of materials, workmanship, or alignment. During each test operation, inspect the hydraulic lines and components for evidence of leakage. Read and record the pressure in the supply and return lines for each direction of operation. Inspect response of components to operation of applicable controls to confirm that all connections have been made properly.

3.8.3.3 Test Reports

Prepare and complete test reports showing in detail the results of the shop and field test. Test reports include a detailed tabulation showing values of pressures, flow rates, and all adjustments recorded during the final tests, and adjustment and calibration of the entire system. During each test run, record the following data and observations:

a. Control operation

b. Voltages

c. Currents

d. Pressures

e. Speeds and times

f. Flow control valve settings

g. Alignment and operating clearances

h. Excessive vibration

i. Pertinent observations regarding such events as unusual sounds, malfunctions or difficulties encountered, and adjustments required.

3.9 OPERATION AND MAINTENANCE

Submit Operation and Maintenance manuals for all valves and custom fabrications furnished for this project. Furnish 3 complete sets of instructions containing the manufacturer's operation and maintenance instructions for the cylinder to the Contracting Officer. Furnish one complete set prior to field testing and furnish the remaining sets before the contract is completed. The instruction sheets must be approximately 8 1/2 by 11 inches, with large sheets of drawings folded in.

-- End of Section --

SECTION D DRAWINGS

MITER GATE CYLINDERS

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